Systems and Methods for Packaging and Distributing Stretch Film Rolls

ABSTRACT

A method of bundling rolls of film together includes at least: placing at least two rolls of film, each of the rolls comprising an axis, an outer surface, and first and second ends, into tangential contact with each other, so that the axes of the rolls are parallel to each other; and securing said rolls together. A bundled package includes at least: at least two rolls of film in tangential contact with each other, each of said rolls having an axis, an outer surface, and first and second ends, wherein the axes of said rolls are parallel to each other; and a securing means for bundling the at least two rolls together.

STATEMENT OF RELATED CASES

The present application claims the benefit of prior U.S. provisional application No. 61/885,165, filed on Oct. 1, 2013, the contents of which are incorporated herein in their entirety.

FIELD

The present invention relates generally to stretch films, and in a particular though non-limiting embodiment, to methods and systems for packaging and distributing stretch film rolls via bundling, without using excessive, additional packaging.

BACKGROUND

In the unitizing arena, stretch films are widely used to secure loads. Stretch films are utilized in a variety of bundling and packaging applications including securing boxes, merchandise, produce, equipment, parts, and other similar items onto pallets.

After manufacturing the stretch film and winding the finished stretch film product onto rolls, stretch film manufacturers package and ship the film rolls to their purchasers through normal distribution channels, such as standard package carriers, wherein the stretch film rolls may be flown and/or driven to their final destination.

To prevent damage to the film rolls during shipping and handling, which can result in rendering the film unusable, stretch films manufacturers provide protection to the film rolls, such as boxing and palletizing the rolls for shipment.

However, boxing and palletizing the rolls results in further costs to produce, transport, and sell the product, due to the cost of the packaging materials and the man-hours required to package the rolls. It also results in an environmental impact, due to the increased amount of materials used to ship the product. Most of the products in the stretch film market use this type of packaging due to the inability of the products to absorb even moderate abuse.

Pre-stretched and oriented films are becoming more popular in the stretch film industry. Due to the incorporation of air into the roll, pre-stretched and oriented films are more inherently resistant to abuse than traditional stretch film products. These types of products are able to undergo the rigors of being dropped and general handling during transportation without losing their ability to unwind and function properly. However, the incorporation of air throughout the film roll also significantly lowers the weight per volume of these products, resulting in a much higher cost of shipping (i.e., shipping air with the film).

There are currently no known methods and systems for bundling stretch film products that do not require the use of expensive packing materials.

There is, therefore, a long-standing yet unmet need for systems and methods for packaging and shipping stretch film rolls in a more economical and environmentally friendly way, while still ensuring the protection of the film rolls during shipment to the end user.

SUMMARY

Bundled packages of film rolls and methods for bundling rolls of film together are provided herein. A method of bundling rolls of film together includes at least the following steps: placing at least two rolls of film, each of the rolls comprising an axis, an outer surface, and first and second ends, into tangential contact with each other, so that the axes of the rolls are parallel to each other; and securing said rolls together.

A bundled package includes at least the following: at least two rolls of film in tangential contact with each other, each of said rolls having an axis, an outer surface, and first and second ends, wherein the axes of the rolls are parallel to each other; and a securing means for bundling the at least two rolls together. In some embodiments, the securing means is a wrapping material. The wrapping material wraps around a portion of the outer surfaces of the rolls, between the first and second ends, approximately perpendicular to the axes of the rolls, thereby securing the rolls together.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a bundled package of film rolls, according to an example embodiment.

FIG. 2 illustrates the bundled package from FIG. 1, from a top view, according to an example embodiment.

FIG. 3 illustrates a bundled package with a separate handle, according to a further embodiment.

DETAILED DESCRIPTION

The following description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating example embodiments.

In certain embodiments, pre-stretched and oriented stretch films provide an opportunity to package and distribute these products in a novel system that minimizes the use of conventional packaging systems.

According to example embodiments, bundling and shipping stretch film rolls to the end user without excessive, additional packaging results in improved economics and more environmentally-friendly systems and methods.

In example embodiments, a securing means for bundling rolls of film in tangential contact with each other together is provided.

According to further example embodiments, an overwrap bundling film is used to provide containment for the film rolls.

According to still further embodiments, the system is able to deliver the film rolls through ordinary distribution channels to the end-user in a useable and functional manner.

Turning now to FIG. 1, the bundled package 100 has an inner portion of the film rolls 101 wrapped together with a film web 102, according to example embodiments.

As shown in FIGS. 1 and 2, in example embodiments, a single wrap 103 around the middle of the rolls 101 serves as a handle.

In an alternative embodiment, an adhesive-backed tape is used as a handle, which is applied directly to the film rolls 101 or the film web 102.

In certain embodiments, a tacky, clingy, or in some embodiments, a non-slip film is utilized as a handle. In an example embodiment, the tacky, clingy, or non-slip film is applied to the rolls of film, and then over-wrapped with the bundling material film web.

In further embodiments, a film with sufficient strength to support the weight of the rolls without significant stretching or breaking serves as a handle. In some embodiments, taping material produced from nylon, polyester, polypropylene, or any web-backed product is utilized.

In alternative example embodiments, the bundled package 200 comprises a plurality of portions of film rolls 201 wrapped together with a film web 202, as illustrated in FIG. 3.

In other embodiments, a separate handle 203 is attached to the bundled package 200 in a secondary operation. In still further embodiments, a label 204 is affixed to the bundled package 200.

In still other embodiments, the bundling is accomplished via a shrink wrap, similar to how paper towels are packaged for bulk sale.

According to example embodiments, securing means for bundling rolls of film together is a wrapping material. In some embodiments, the wrapping material is a film web, tape, stretch film, elastic film, or shrink film (IR, heat tunnel or heat gun initiated). In other example embodiments, the wrapping material is a compression band.

According to example embodiments, the bundling operations are performed manually, semi-automatically, or fully automatically, depending on the design and operation of the wrapping equipment.

In example embodiments, the number of revolutions required around the bundle is dependent on the thickness, toughness, and modulus of the bundling material.

According to one example embodiment, a plurality of rolls of oriented hand film are packaged on a semi-automated bundling machine, utilizing an about 20 micron thick, about 4 inch wide stretch bundling film to impart four to five wraps around the rolls. In further example embodiments, four rolls of oriented hand film are packaged together using film.

The foregoing specification is provided only for illustrative purposes, and is not intended to describe all possible aspects of the present invention. While the invention has herein been shown and described in detail with respect to several exemplary embodiments, those of ordinary skill in the art will appreciate that minor changes to the description, and various other modifications, omissions and additions may also be made without departing from the spirit or scope thereof. 

1. A bundled package, comprising: at least two rolls of film in tangential contact with each other, each of said rolls having an axis, an outer surface, and first and second ends, wherein said axes of said rolls are parallel to each other; and a securing means for bundling said at least two rolls together.
 2. The bundled package of claim 1, wherein said securing means is a wrapping material, further wherein said wrapping material wraps around a portion of said outer surfaces of said rolls, between said first and second ends, approximately perpendicular to said axes of said rolls, thereby securing said rolls together.
 3. The bundled package of claim 2, wherein said wrapping material is a stretch film.
 4. The bundled package of claim 2, wherein said wrapping material is a shrink film.
 5. The bundled package of claim 2, wherein said wrapping material is a compression band.
 6. The bundled package of claim 2, further comprising a handle connected to said wrapping material.
 7. The bundled package of claim 6, further comprising a label affixed to an outside surface of said wrapping material.
 8. A method of bundling rolls of film together, comprising: placing at least two rolls of film, each of said rolls comprising an axis, an outer surface, and first and second ends, into tangential contact with each other, so that said axes of said rolls are parallel to each other; and securing said rolls together.
 9. The method of claim 8, further comprising wrapping a wrapping material around a portion of said outer surfaces of said rolls, between said first and second ends, approximately perpendicular to said axes of said rolls.
 10. The method of claim 8, further comprising securing said rolls together using a stretch film.
 11. The method of claim 8, further comprising securing said rolls together using a shrink film.
 12. The method of claim 8, further comprising securing said rolls together using a compression band.
 13. The method of claim 8, further comprising connecting a handle to said wrapping material.
 14. The method of claim 8, further comprising affixing a label to an outside surface of said wrapping material.
 15. The method of claim 9, further comprising wrapping said wrapping material around said rolls five times. 